# How to reduce freight cost with better packaging

Freight is charged on space as much as weight, so the cheapest savings come from packaging: cartons sized to the pallet and container, less void fill, the right pallet footprint, full layers and tiers, and choosing between LCL, FCL, air and express by chargeable weight rather than habit.

## Key takeaways

- Measure what you are charged on: CBM, revenue tons or chargeable weight.
- Fit cartons to the pallet and pallets to the container; whole numbers win.
- Cut void fill and nest or flat-pack products where possible.
- Re-quote the mode: a near-full LCL shipment may be cheaper as FCL.

## 1. Know what you are paying for

Sea LCL charges per revenue ton (the larger of m³ and tons), FCL per container, air and express per chargeable weight. Look at your last invoices and work out whether you were charged on volume or weight; that tells you where packaging can help. The [CBM calculator](https://cartonmath.com/cbm-calculator/) shows all three.


## 2. Right-size the carton

A carton 1 cm too big each way can cost whole layers: 41 × 31 × 21 cm cartons fit 30 per EUR pallet against 56 for 40 × 30 × 20 cm. See [choosing carton dimensions](https://cartonmath.com/guides/export-carton-dimensions/).


## 3. Remove air

- Use inserts or fitted pulp trays instead of loose fill.
- Nest products (bowls, buckets, chairs) or ship knocked down.
- Compress soft goods such as textiles and bedding with vacuum bags.
- Reduce outer packaging layers that do not add protection.


## 4. Choose the pallet that fits the route

EUR pallets fill a container floor best (25 in a 40 ft box against 20 US 48 × 40 in pallets), but the destination warehouse decides what it accepts. Compare in [pallet sizes explained](https://cartonmath.com/guides/pallet-sizes-eur-us-iso/).


## 5. Fill the container

If the order nearly fills a container, ask the buyer whether a few more cartons can go in: the extra goods ship for free under FCL. If it is far from full, compare LCL. Use the [container calculator](https://cartonmath.com/container-loading-calculator/) to see the exact count.


## 6. Pick the mode by chargeable weight

Light, bulky goods are expensive by air because they are charged on volume. Dense goods can be good value by air or express when speed matters. Run both numbers before deciding (see [air chargeable weight](https://cartonmath.com/guides/air-freight-chargeable-weight/)).


## 7. Protect without overpacking

Damage claims cost more than freight. Use test results (drop tests, compression tests) to decide board grade and inserts, then remove anything that does not help. Strong, snug cartons in column stacks often allow taller pallets, which also saves space.

[Start with your carton](https://cartonmath.com/pallet-calculator/): See how many fit a pallet, then a container.

## FAQ

**What is the easiest way to cut freight cost?**
Check whether you are charged on volume or weight, then reduce the one that drives the bill, usually by right-sizing cartons and removing void fill.

**Do smaller cartons always save money?**
Not always: more cartons cost more board and handling. The best carton fits the pallet and container in whole numbers and protects the goods.

**Is FCL cheaper than LCL?**
Above a break-even volume that depends on the route and the market; compare both quotes.

**Does pallet choice affect freight cost?**
Yes. Different footprints fit containers differently, and the wrong pallet may need re-palletising at destination.

Source page: https://cartonmath.com/guides/reduce-freight-cost-packaging/
Updated: 2026-10-06
Publisher: CartonMath (https://cartonmath.com)